Man, do I need some help. I am hoping someone on the forum has run across this problem or has heard of it before. This problem has totally stumped 2 Suzuki dealers so far, and they have thrown up their hands over the problem.
My 2003 Hayabusa wont start, is trying to fire out of sequence, and is randomly sputtering.
So far, here is what has gone on. Jim Palmers, the largest Suzuki dealer in Daytona Beach, worked on the bike for 14 hours, all to no avail. The bike has been in a shop in Houston, Texas for two weeks, with no progress in sight. Who ever can solve this problem will be a Super Hero in my book and to the other mechanics who have worked on the bike so far.
Here is the history of the bike, the problem, and the attempted fixes. I bought the modified 2003 Busa 8 months before the problem began. The bike ran fine before I began to clean and dress it up for Bikeweek. Yes, I admit, I broke it.
Modifications to the bike are as follows.
1397†bore; Yoshimura cams; valves and springs; JE pistons; Heads ported and polished; Revtech commander; new lighting on the front and back; additional fan, misc chrome and dress ups.
The problem with the bike is:
The bike will try to start, but it is firing out of sequence, and will only pop and sputter randomly. Fuel delivery seems to be fine.
Here is what I did just previous to the problem. All the plastic was removed so I could deep clean the bike. I thought I may have been a little to aggressive with the brushes, cleaner and water, so I went back and sprayed wd-40 in all of the connections and rechecked the wiring as best I could. Some of the wiring done by the previous owner was not tight so I tried to clean it up. New plugs were installed and the K&N was cleaned. I replaced gaskets on the exhaust emission tubes to clear up an exhaust leak.
I replaced the Stator cover with a CHROMED cover at the same time, and this is where I think the problem lies. I worked with the mechanic at the Daytona shop, and when we got around to taking the stator cover off, we found the sensor contact pick up was slightly loose. The threads had some chrome down in them and it allowed the contact to moved a little back and forth. I did not catch this when I switched covers. We tapped out the threads and reinstalled. Before we took the stator cover off, the bike would try to start and would sputter. After reinstalling the stator cover with the contact tightened , the bike would not try to start or sputter at all. The voltage tested fine, so the mechanic moved on. A new ecu unit was plugged in from a 2005 Busa, the power commander disconnectd, plugs replaced, and a new cam sensor bought and replaced, and hours were poured into the bike.
When none of this worked, we pulled the cams out, as the mechanic thought they were off by one tooth, and he reset them. We did not change the degree of the cams. I protested the cam change as I know they did not jump a tooth, and the bike ran great before, but he was the master mechanic of the shop, so I took the back seat. We were getting codes that said the cam sensor was bad so the sensor was replaced, and all of the other sensors were checked out. After 14 hours of working on the bike, charging me for only 2 hours, they threw in the towel and gave the bike back.
While at the Daytona Track before the Aria 200, I talked to Derek, the top Technician for Suzuki. Explaining the problem to him, he said the air gap between stator contact pickup and the engine flywheel was critical, and if it is off, it will change the voltage and allow the sensors to give false readings. I bought another stator from a 2002 (I think), and compared it to the existing one. When the old stator sensor pick up was loose, you could see where it had barely scrapped the contact, so I replaced the stator. The Houston mechanic seems to think it is registering the proper voltage, high on one end, low on the other, but within tolerance, and now the bike is back to at least sputtering, but not starting. I am installing a different non chromed stator cover this week hoping it may have something to do with the problem. We are waiting for information from Yoshimura about the cam position, but I don’t think that was the problem to begin with.
If anyone has any ideas or cures, or can lead me to someone who might, please help.
I can be contacted at bill@theroofco.com
My 2003 Hayabusa wont start, is trying to fire out of sequence, and is randomly sputtering.
So far, here is what has gone on. Jim Palmers, the largest Suzuki dealer in Daytona Beach, worked on the bike for 14 hours, all to no avail. The bike has been in a shop in Houston, Texas for two weeks, with no progress in sight. Who ever can solve this problem will be a Super Hero in my book and to the other mechanics who have worked on the bike so far.
Here is the history of the bike, the problem, and the attempted fixes. I bought the modified 2003 Busa 8 months before the problem began. The bike ran fine before I began to clean and dress it up for Bikeweek. Yes, I admit, I broke it.
Modifications to the bike are as follows.
1397†bore; Yoshimura cams; valves and springs; JE pistons; Heads ported and polished; Revtech commander; new lighting on the front and back; additional fan, misc chrome and dress ups.
The problem with the bike is:
The bike will try to start, but it is firing out of sequence, and will only pop and sputter randomly. Fuel delivery seems to be fine.
Here is what I did just previous to the problem. All the plastic was removed so I could deep clean the bike. I thought I may have been a little to aggressive with the brushes, cleaner and water, so I went back and sprayed wd-40 in all of the connections and rechecked the wiring as best I could. Some of the wiring done by the previous owner was not tight so I tried to clean it up. New plugs were installed and the K&N was cleaned. I replaced gaskets on the exhaust emission tubes to clear up an exhaust leak.
I replaced the Stator cover with a CHROMED cover at the same time, and this is where I think the problem lies. I worked with the mechanic at the Daytona shop, and when we got around to taking the stator cover off, we found the sensor contact pick up was slightly loose. The threads had some chrome down in them and it allowed the contact to moved a little back and forth. I did not catch this when I switched covers. We tapped out the threads and reinstalled. Before we took the stator cover off, the bike would try to start and would sputter. After reinstalling the stator cover with the contact tightened , the bike would not try to start or sputter at all. The voltage tested fine, so the mechanic moved on. A new ecu unit was plugged in from a 2005 Busa, the power commander disconnectd, plugs replaced, and a new cam sensor bought and replaced, and hours were poured into the bike.
When none of this worked, we pulled the cams out, as the mechanic thought they were off by one tooth, and he reset them. We did not change the degree of the cams. I protested the cam change as I know they did not jump a tooth, and the bike ran great before, but he was the master mechanic of the shop, so I took the back seat. We were getting codes that said the cam sensor was bad so the sensor was replaced, and all of the other sensors were checked out. After 14 hours of working on the bike, charging me for only 2 hours, they threw in the towel and gave the bike back.
While at the Daytona Track before the Aria 200, I talked to Derek, the top Technician for Suzuki. Explaining the problem to him, he said the air gap between stator contact pickup and the engine flywheel was critical, and if it is off, it will change the voltage and allow the sensors to give false readings. I bought another stator from a 2002 (I think), and compared it to the existing one. When the old stator sensor pick up was loose, you could see where it had barely scrapped the contact, so I replaced the stator. The Houston mechanic seems to think it is registering the proper voltage, high on one end, low on the other, but within tolerance, and now the bike is back to at least sputtering, but not starting. I am installing a different non chromed stator cover this week hoping it may have something to do with the problem. We are waiting for information from Yoshimura about the cam position, but I don’t think that was the problem to begin with.
If anyone has any ideas or cures, or can lead me to someone who might, please help.
I can be contacted at bill@theroofco.com
